Method for producing a three-dimensional component

ABSTRACT

A method for producing a three-dimensional component by means of a laser melting process, in which the component is produced by consecutively solidifying individual layers made of building material by melting the building material, wherein said building material can be solidified by the action of radiation, wherein the melting area produced by a punctiform and/or linear energy input is detected by a sensor device and sensor values are derived therefrom in order to evaluate the component quality. The sensor values detected in order to evaluate the component quality are stored together with the coordinate values that locate the sensor values in the component and are displayed by means of a visualization unit in two- and/or multi-dimensional representation with respect to the detection location of the sensor values in the component.

This application is a Continuation of U.S. application Ser. No. 15/904,272, filed Feb. 23, 2018, currently pending, which is a Divisional of U.S. application Ser. No. 13/812,446, filed Jan. 25, 2013, which was a U.S. 371 National Stage entry of International Application Serial No. PCT/DE2011/001088 filed May 19, 2011, which claims priority to German Application No. 20 2010 010 771.7 filed Jul. 28, 2010. The contents of each of these applications are hereby incorporated herein by reference in their entirety as if set forth verbatim.

BACKGROUND OF THE INVENTION

The present disclosure relates to a method for producing a three-dimensional component by a laser melting process, in which the component is produced by successive solidification of individual layers of building material which can be solidified by the action of radiation, by fusing the building material, having the further features of the preamble of claim 1.

Moreover, the present disclosure also relates to a device for carrying out this method and to the use of a visualization apparatus for two-dimensional or multidimensional, preferably 2D or 3D, representation of component regions of components produced in generative fashion by the action of radiation on powder-like building material in respect of the component quality thereof.

DISCUSSION OF RELATED ART

WO 2007/147221 has disclosed a device and a method for monitoring and for controlling a selective laser melting construction process. The illustrated device for selective laser powder processing comprises a build platform with a powder bed, a powder deposition system for applying a powder surface to the build platform, a laser, the focused laser beam of which impinges on the powder surface and causes the powder to melt within a melt zone. The laser beam is guided over the powder surface by means of a scanner device. Moreover, provision is made for a detector for capturing electromagnetic radiation which is emitted or reflected by the powder surface and interacts with an optical system that follows the laser beam and is suitable for guiding the radiation in the direction of the detector.

The detector of the known device is embodied such that it can capture the electromagnetic radiation emitted or reflected by a moveable observation region on the powder surface, wherein the moveable observation region is greater than the minimum laser spot of the laser beam. As a result, it is possible to capture the melt pool created in the powder bed.

The detector can be used to establish the size of the melt zone, in particular the length and width and a length-to-width ratio. Moreover, it is possible to select specific parts of the electromagnetic spectrum of the radiation emitted by the melt pool.

SUMMARY

In accordance with the present disclosure there is provided a method having the features of the preamble of claim 1 and an associated device for carrying out the method such that the values captured thereby can be evaluated more easily. This object is achieved by virtue of the fact that sensor values captured for evaluating component quality are stored together with coordinate values localizing the sensor values in the component and are displayed by means of a visualization apparatus in a 2D or 3D representation in respect of the capture location thereof in the component.

In other words, the object is achieved by virtue of the fact that the sensor values captured for evaluating the component quality are stored together with the coordinate values localizing the sensor values in the component and are displayed by means of a visualization apparatus in two-dimensional and/or multidimensional representations in respect of the capture location thereof in the component. The sensor device is able to operate, preferably in respect of the dimensions, shape and/or temperature of the effects of the point- and/or line-shaped energy influx detected in the melt region.

In a preferred embodiment, sensor values of a component plane are displayed in the case of a 2D representation, which sensor values correspond to a layer which is solidified by the action of radiation from a new deposition of building material. In particular, it is advantageous if sensor values of a freely selectable component sectional plane are displayed in the case of a 2D representation, which plane extends at an angle (e.g. at right angles or at an angle less than 30°) to a layer successively solidified by the action of radiation. In particular, the sectional plane can be freely selectable both in terms of its angle and in terms of its position within the fictitious installation space on the screen of the visualization apparatus, similar to what is also the case in commercially available 2D/3D CAD computer programs.

Furthermore, it is advantageous if in the case of a two-dimensional and/or multidimensional representation only sensor values are displayed visually and/or highlighted which represent component regions which, compared to at least one definable (predefined) intended degree of solidification or intended temperature value or intended density value, have a deviating, more particularly reduced, degree of solidification or temperature value or density value. It is likewise possible, in addition to the degree of solidification, the temperature value and the density value, also to use an intended energy influx and/or intended melt pool dimensions as a basis for displaying the deviation and/or highlighting.

By way of example, these regions can be highlighted by a targeted selection of different colors, grayscale values, degrees of transparency and/or in respect of an areal structure (shading type such as dotted, respectively obliquely ruled at different angles, etc.).

Furthermore, the coordinate values localizing the sensor values in the component can, at least in part, be the component coordinates used to produce the component. It is likewise possible to position or localize or assign the sensor values to a coordinate value both by means of using the build coordinate values (the information underlying the building process) and, exclusively or additionally, by means of using localization sensors detected during the building process by means of further sensors.

In a further advantageous embodiment, coordinates are assigned to the sensor values by means of exposure data or scanner data. Additionally, or as an alternative thereto, it may also be advantageous if during the areal capture of the whole build plane or the section comprising the component cross section the coordinates of a radiation energy influx of the component plane are captured and assigned to the sensor values and the position of the component plane (Z coordinate) is captured separately.

These days, visualization apparatuses are used in conjunction with X-ray and computed tomography technology and generally serve to display sensor values which are captured metrologically as a result of the named methods in an existing, i.e. present in the completed state, body.

The visualization method and an associated visualization device (software) of the present disclosure are implemented in conjunction with a generative production process and are used to display values captured in the melt pool during the building process in a more effective fashion in order, directly after the completion of and/or still during the building process, to provide an operator of such a laser melting apparatus with information as to whether the solidified component layers satisfy the requirements placed on the component in respect of fusion, temperature profile, work piece solidity, etc. Should a component produced in generative fashion be found not to be solid enough and at a later date give rise to a user complaint, then e.g. archived, build-historic visualization information can be used to check very quickly whether e.g. a breakpoint of the tool was in actual fact produced according to the design specifications or whether there were upward or downward deviations (e.g. in tolerance ranges). It is possible to check, particularly if fine structures are present within the component, whether the degree of fusion, the temperature profile after heat reductions, the component density and the like were set in such a fashion there that breakage should be avoided. For future building projects, such insight can be used to avoid work piece breakage and/or material failure.

When claim 1 refers to a two-dimensional or multidimensional representation, this means either that a two-dimensional image of the visualized sensor values is displayed, with the sensor values lying in a sectional plane, e.g. a component plane, or in a plane extending at an angle to the build plane, or that in the case of a 3D representation the component is displayed in virtually transparent fashion and adjustments of the component quality are illustrated on the basis of the established sensor values and the coordinate values, e.g. build coordinate values, correlated thereto.

In a development of the method, it is possible in the case of a 2D or 3D representation only to visually filter out sensor values which represent component regions which, compared to a definable intended degree of solidification, have a deviating, more particularly reduced, degree of solidification. Naturally, the same also applies to representations of e.g. the melt temperature, the density and the like.

In the process, an optimized value can be displayed in a first color, a first grayscale value and/or with a first areal structure and values deviating upward or downward from this optimized value are displayed differently in terms of color, grayscale value and/or in respect of the areal structure (e.g. the type of shading). This allows an observer of such a 2D or 3D image immediately to obtain information in respect of whether the building process proceeded in an optimal fashion or whether the component may, under certain circumstances, have weaknesses.

The coordinate values localizing the sensor values in the component can be the build coordinate values used to produce the component. These are the values which are used to guide the laser beam over the powder surface and values that represent a Z coordinate in respect of the layer number. However, it is also possible to newly obtain the coordinate values localizing the sensor values in the component when capturing the sensor values, i.e. to scan the component surface to be solidified at this time using a suitable scanning method and to store values that correspond to a solidification point (point of energy influx into the powder bed) in the layer. This can be brought about by virtue of the fact that either there is an areal capture of the whole build plane or all that is captured is only a section of interest in the build plane, which contains the component region.

Provision is also made within the scope of the present disclosure for the sensor values to be captured not directly at the moment of the energy influx but, additionally or alternatively, offset in time thereafter. By way of example, if the temperature in the melt pool is captured at a time TO (during the energy influx) and then at later times, e.g. 0.5 seconds, 1 second, 1.5 seconds or the like, it is then possible to obtain information about the heat flux in the component during the building process from sensor values to be visualized thus in order, for example, to avoid overheating effects in the case of very fine component interior regions. By way of example, such time-offset capturing methods are referred to as sampling microscope methods in microscopy.

In addition to the conventional components of a laser melting apparatus with a sensor device as per WO 2007/147221 A1, the device for carrying out the method of the present disclosure additionally comprises a storage apparatus, in which the sensor values captured for evaluating the component quality are stored together with coordinates localizing the sensor values in the component, and a visualization apparatus, which is connected to the storage apparatus and by means of which it is possible to display the stored sensor values in e.g. a 2D or 3D colored or grayscale representation in respect of the capture value thereof in the component.

BRIEF DESCRIPTION OF THE DRAWINGS

The method and apparatus of the present disclosure are explained in more detail with reference to the figures. In these:

FIG. 1 shows a schematic illustration of a coaxial monitoring process system using two vectors as per the prior art;

FIG. 2 shows a schematic illustration of a typical selective laser process machine with means according to the present disclosure for capturing and evaluating the sensor values; and

FIG. 3 shows a flowchart which illustrates essential processes of a preferred method according to the present disclosure.

DETAILED DESCRIPTION

FIG. 1 illustrates a device according to the prior art, wherein this device comprises a method for producing a three-dimensional component 1 by a laser melting process. The component 1 is produced by successive solidifying of individual layers 2 (indicated as dashed line) of building material 4 which can be solidified by the action of radiation 3, by fusing the building material 4. The melt region 5 created by a point- and/or line-shaped energy influx is captured by a sensor device 6 (e.g. camera 11 and photodiode 12) in terms of its dimensions, shape and/or temperature, and the sensor values resulting therefrom are derived for evaluating component quality.

In the illustrated embodiment of the prior art as per FIG. 1 , the radiation 3 is generated by a laser source 7 (laser). It is subsequently deflected by a semi-reflective mirror 8 and guided to the layer 2 to be solidified of the building material 4 via a scanner 9 with preferably a focusing lens. The radiation generated at the melt region 5 travels this path in the opposite direction and passes through the semi-reflective mirror 8 in a straight line such that said radiation reaches a beam splitter 10 and there, if deflected, it is guided to a first detector, preferably a camera 11, and, when passing straight through the beam splitter 6, it is guided to a second detector, for example a photodiode 12.

FIG. 2 now illustrates the extension of the system known from the prior art. The component 1 which is assembled on a base plate 14 in the build region on a height-displaceable support 13 using said base plate 14 is assembled layer-by-layer (cf. layer 2) in the powder bed of the powdery building material 4. A deposition apparatus 15 transports the building material 4 to the build region from a metering chamber 26.

Proceeding from a laser 7, the radiation 3 is directed at the component 1 via the scanner 9 after passing straight through a mirror 16 that can be passed through from one side. The radiation reflected by the component is guided via the scanner 9 and the mirror 16, which is completely reflective in this direction, to a further deflection mirror 17 and finally to a detector of a sensor apparatus 6, 11, 12, 18. This detector transmits a signal to a processor 19, preferably a microprocessor, the output of which reaches a storage medium 20.

The laser 7 is preferably provided with a beam manipulation apparatus 21, which for example is designed in the style of a mode aperture, a grating filter or other optical elements. This beam manipulation apparatus 21 is actuated by a controller 22, the control data of which, like the processor data from the processor 19 stored in the storage medium 20, merge in a data linkage and/or data assignment unit 23. It is likewise possible in the data linkage/data assignment unit 23 to collect and assign to one another control data from the scanner 9 and/or control data in respect of the height displacement of the support 13, preferably by means of the actuator 24 thereof. Naturally, it is also possible to supply to the data linkage/data assignment unit 23 control data from the depositor of the deposition apparatus 15 and/or of the supply mechanism for building material for a corresponding component layer 2 (by way of example, this could be realized by the control data from the actuator 25 of the metering chamber 26). It is also possible for a control module 27 of the scanner to be arranged between the scanner 9 and the data linkage/data assignment unit 23. The data collected in the data linkage/data assignment unit 23 and assigned to one another (e.g. data tuple) can then be processed further in a further data processing unit 28 and/or be visualized via a visualization element 29. It is also possible to provide an interface for a data storage medium instead of a data processing unit 28. For example, a monitor, a beamer or a holograph can all be used as visualization element.

Finally, the sensor values captured for evaluating the component quality are stored together with the coordinate values localizing the sensor values in the component 1 and said sensor values are displayed, in relation to the point of capture in the component 1, in two-dimensional and/or multidimensional representations by means of the visualization apparatus 29.

FIG. 3 in an exemplary fashion illustrates an advantageous process of the method according to the present disclosure. The process control acts on the laser 7 and/or the scanner 9 and regulates the properties of the laser beam 3 via the laser vector [n]. The building material 4 is exposed proceeding from the scanner 9, as a result of which a melt or the melt region 5 forms. Radiation is emitted from the melt region 5 and it is detected by the sensor device 6, 11, 12, 18. The result of this detection leads to an evaluation (e.g. according to the length, width, area, etc.), leading to temporary storage of the evaluation. This temporarily stored evaluation is subjected to so-called mapping. This mapping is preferably based on definable/modifiable mapping parameters (contrast, color, detector selection, threshold regions, etc.). Post mapping, this is displayed by the visualization apparatus 29 and/or stored. In doing so, it is advantageous if the mapping parameters also underlie the storage and/or the representation, i.e. that the mapping parameters are also stored and/or also displayed by the visualization apparatus 29.

While the method and apparatus of the present disclosure have been described with reference to certain embodiments, numerous modifications, alterations and changes to the described embodiments are possible without departing from the spirit and scope of the present disclosure, as defined in the appended claims. Accordingly, it is intended that the method and apparatus of the present disclosure not be limited to the described embodiments, but that it has the full scope defined by the language of the following claims, and equivalents thereof. 

The invention claimed is:
 1. A method of additively manufacturing a three-dimensional component by a laser melting process, the method comprising: selectively solidifying sequential layers of a powdered build material with radiation from a radiation source comprising an energy influx, the energy influx having a point shape and/or a line-shape, the radiation causing a melt region within a build plane defined by the powdered build material, the melt region solidifying to form a three-dimensional component; capturing sensor values from the melt region using a sensor device; generating a component quality output based at least in part on the sensor values; and evaluating a quality of the three-dimensional component based at least in part on the component quality output, the component quality output being used to accept, reject, or modify the three-dimensional component.
 2. The method of claim 1, comprising: displaying at least some of the sensor values in a 2D representation, the sensor values corresponding to a layer solidified by the radiation prior to a next deposition of powdered build material.
 3. The method of claim 1, comprising: displaying at least some of the sensor values in a 2D representation in the form of a freely selectable sectional plane of the three-dimensional component, the sectional plane extending at an angle to a layer solidified by the radiation.
 4. The method of claim 1, comprising: displaying, in a two-dimensional representation and/or a multidimensional representation, a portion of the sensor values corresponding to regions of the three-dimensional component that exhibit a deviation from an intended sensor value, the sensor values and the intended sensor values being indicative of density, degree of solidification, temperature, energy influx, and/or melt pool dimensions, the deviation from the intended sensor value displayed visually and/or highlighted.
 5. The method of claim 1, comprising: displaying the component quality output in a two-dimensional and/or multidimensional representation in respect of the capture location thereof in the three-dimensional component.
 6. The method of claim 5, comprising: displaying the component quality output, wherein displaying the component quality output comprises: displaying one or more sensor values representing an optimized value in a first color, a first grayscale value, a first degree of transparency and/or with a first areal structure; and displaying one or more sensor values representing a deviation upward or downward from the optimized value in a second color, a second grayscale value, a second degree of transparency and/or in respect of a second areal structure.
 7. The method of claim 1, comprising: localizing the sensor values to the three-dimensional component and evaluating the quality of the three-dimensional component based at least in part on the component quality output.
 8. The method of claim 7, comprising: determining coordinate values localizing the sensor values to the three-dimensional component based at least in part on build coordinate values used to produce the three-dimensional component.
 9. The method of claim 7, comprising: determining the coordinate values based at least in part on sensor value coordinates obtained when capturing the sensor values and using the coordinate values to localize the sensor values to the three-dimensional component.
 10. The method of claim 9, comprising: determining the sensor value coordinates based at least in part on an areal capture of at least a portion of the build plane, the at least a portion of the build plane including the melt region.
 11. The method of claim 7, comprising: assigning coordinates to the sensor values based at least in part on exposure data or scanner data.
 12. The method of claim 1, comprising: capturing at least some of the sensor values with a time delay with respect to the time of the energy influx; and displaying the component quality output, wherein the component quality output comprises a visualization that exhibits a time profile of a thermal behavior of the melt region.
 13. The method of claim 1, comprising: capturing, for a given location on the build plane, a plurality of the sensor values with respectively different time delays with respect to the time of the energy influx at the given location on the build plane.
 14. The method of claim 1, wherein the three-dimensional component is modified during solidification of the powdered build material.
 15. A method additively manufacturing a three-dimensional component, the method comprising: selectively solidifying sequential layers of a powdered build material with radiation from a radiation source comprising an energy influx, the energy influx having a point shape and/or a line-shape, the radiation causing a melt region within a build plane defined by the powdered build material, the melt region solidifying to form a three-dimensional component; capturing sensor values from the melt region using a sensor device; and generating a component quality output based at least in part on the sensor values for use in accepting, rejecting, or modifying the three-dimensional component, wherein generating the component quality output comprises correlating the sensor values with coordinate values of the component.
 16. The method of claim 15, comprising: correlating the sensor values with coordinate values of the component based at least in part on scanner data; and localizing the sensor values to the component quality output for the three-dimensional component.
 17. The method of claim 15, comprising: evaluating a quality of the three-dimensional component based at least in part on the component quality output; and displaying the component quality output in a two-dimensional and/or multidimensional representation of at least a portion of the three-dimensional component and a capture location of the sensor values in the three-dimensional component.
 18. A method of additively manufacturing a three-dimensional component, the method comprising: selectively solidifying sequential layers of a powdered build material with radiation from a radiation source comprising an energy influx, the energy influx having a point shape and/or a line-shape, the radiation causing a melt region within a build plane defined by the powdered build material, the melt region solidifying to form a three-dimensional component; capturing sensor values from the melt region using a sensor device; generating a component quality output based at least in part on the sensor values for use in accepting, rejecting, or modifying the three-dimensional component; and correlating the sensor values with coordinate values of the component.
 19. The method of claim 18, comprising: localizing the sensor values to the three-dimensional component; and evaluating a quality of the three-dimensional component based at least in part on the component quality output, the component quality output being used to accept, reject, or modify the three-dimensional component.
 20. The method of claim 19, comprising: displaying the component quality output in a two-dimensional and/or multidimensional representation in respect of the respective capture location in the three-dimensional component of at least some of the sensor values. 